Passive Fall Protection Systems

A “passive” fall protection system refers to a system that is non-dynamic, stationary, and does not move, adapt, or change when in or out of use. They do not require the use of Personal Protective Equipment or active participation from the worker. Typical passive solutions include guardrails, stairrails, hole and opening covers, skylight guards, or netting systems.

Guardrail Systems (Requirements)

    • The top edge height of top rails, or equivalent guardrail system members, is 42 inches (107 cm), plus or minus 3 inches (8 cm), above the walking-working surface except: guardrails on scaffolds manufactured after January 1, 2000, are 38 to 45 inches high and guardrails on scaffolds in service before January 1, 2000, are 36 to 45 inches high.
    • Midrails may be rails, screens, mesh, intermediate vertical members, solid panels, or other equivalent intermediate members (capable of withstanding, without failure, a force of at least 150 pounds).
    • Toeboards must be installed when the potential exists for objects to fall on persons below. Minimum vertical height: 3.5 inches, and capable of withstanding a force of at least 50 pounds.
    • When guardrail systems are used at access ways and hoisting areas, a chain, gate, or removable guardrail section will be installed.
    • When guardrail systems are used around holes or hatches that are used as points of access (such as ladderways), including rooftop ladderways, they will be provided with a self-closing gate that slides/swings away from the hole, or be offset so that a person cannot walk directly into the hole.
    • Guardrail systems used on ramps and runways will be erected along each unprotected side or edge.
    • When guardrail systems are used around holes used for the passage of materials, the hole will not have more than two sides provided with removable guardrail sections to allow the passage of materials. When the hole is not in use, it will be closed over with a secured labeled cover, or a guardrail system will be provided along all unprotected sides or edges.
    • Parapets, when used as passive fall protection, shall meet the requirements of a guardrail system. Parapets can be used in conjunction with a standard guardrail system. Parapets that do not meet guardrail specifications provide no fall protection.

Hole covers (Requirements)

    • Hole covers shall be capable of supporting at least twice the maximum intended load – twice the weight of employees, equipment, materials, maximum axle load of the largest vehicle expected to cross over – and shall be secured to prevent accidental displacement. They shall also be marked with the word “Hole” or “Cover” to provide warning of the hazard.
    • Floor holes for stairways, ladderways, hatchways, and chutes shall have a hinged cover that is closed when not in use, and a guardrail system with no more than one exposed side.

Active Fall Protection Systems

Active fall protection systems involve active participation of the worker. They consist of administrative controls, work rules, procedures, and practices; and personal protective equipment consisting of a full body harness, lanyard, an anchor, lifeline, and connectors such as snap hooks. There are multiple variations to fall arrest and fall restraint systems.

Administrative Controls

Prohibition of Fall Protection Plan

    • NC State shall use methods other than a Fall Protection Plan to protect employees from fall hazards. The use of a Fall Protection Plan in lieu of other fall protection methods is prohibited.
    • The use of a Fall Protection Plan in conjunction with a Controlled Access Zone is prohibited.
    • It is the judgment of North Carolina regulatory agencies that a feasible, less hazardous alternative is always available.
    • Departments wishing to pursue the use of a Fall Protection Plan may request a regulatory variance through NC State Environmental, Health, & Safety and the Office of the General Counsel.

Controlled Access Zone (Construction)

This refers to an area in which certain construction-related work (such as overhand bricklaying) may take place without the use of guardrail systems, personal fall arrest systems, or safety net systems, and access to the zone is controlled.

    • A controlled access zone may only be used when conventional fall protection systems create a greater hazard.
    • A controlled access zone can only be used for overhand bricklaying where there is no exposure to fall hazards associated with hoist areas; holes; ramps, runways and other walkways, and dangerous equipment; and employees do not reach 10 inches or more below the walking or working surface.
    • A controlled access zone used in conjunction with a fall protection plan is prohibited.
    • NC State employees planning to conduct work protected by a Controlled Access Zone shall document a project safety review, including a job hazard analysis for each task or job, and submit it to Environmental, Health & Safety for approval at least 2 weeks prior to the start of work.
    • Refer to the Mandatory Controlled Access Zone

Designated Area

For work In General Industry, this refers to a distinct portion of a roof where work rules and warning lines are used to protect workers and conventional fall protection methods are not required.

IMPORTANT NOTE: Designated Areas are Only permitted for work on low slope roofs (4:12 or less) in general industry applications (not permitted for construction work).

    • A Designated area may only be used under the following conditions:
      • Situation 1- work area is further than 15 ft from fall hazard:
        1. For tasks that are both infrequent and temporary, the competent person must establish and employees shall comply with a work rule to stay at least 15 feet from the fall hazard. No warning line is required.
        2. For tasks that are not infrequent or temporary, a warning line must be placed between the work area and fall hazard, not closer than 15 feet to the fall hazard.
      • Situation 2 – work area is further than 6 ft from the roof edge, but not less than 15 ft (for other work)
        1. Work must be both infrequent and temporary; if not both, a designated area can not be used.
        2. A warning line must be placed between the work area and the fall hazard, not closer than 6 feet to the fall hazard. See the Designated Area Appendix for warning line specifications and requirements.
      • A designated area can not be used when the work area is closer than 6 feet to the fall hazard. Conventional methods such as guardrail, travel restraint, or personal fall arrest must be used.
      • Authorized employees shall be trained on the proper setup and use of a designated area. Training shall include work rules prohibiting movement closer to a fall hazard than the perimeter of the designated area

Warning Line System (Construction)

The use of warning lines in lieu of conventional fall protection is acceptable for construction work where the warning lines are at least 15 feet away from the edge and all of the following criteria are met:

    • A warning line is used 15 feet or more from the edge (or nearest edge of a hole or other fall hazard);
    • The warning line meets or exceeds the requirements specified in the Warning Line Appendix.
    • No work or work-related activity is to take place in the area between the warning line and the fall hazard; and
    • An effective work rule is developed, written, and implemented by a competent person prohibiting employees from going past the warning line. Employee training on the work rule must be conducted.

Warning Line system applicable to construction roofing work only:

    • A warning line may be used for construction roofing work when closer to the fall hazard than 15 feet, but no closer than 6 feet and in conjunction with one of the following:
      • a guardrail system,
      • a safety net system,
      • a personal fall protection system, or
      • a safety monitoring system.
    • A warning line may be used for construction roofing work when closer to the fall hazard than 15 feet, but no closer than 10 feet
    • When mechanical equipment is being used, the warning line shall be erected not less than 6 feet (1.8 m) from the unprotected roof edge which is parallel to the direction of mechanical equipment operation, and not less than 10 feet (3.1 m) from the unprotected roof edge which is perpendicular to the direction of mechanical equipment operation. Mechanical equipment means all motor or human propelled wheeled equipment used for roofing work, except wheelbarrows and mop carts.
    • A warning line system shall conform to regulatory requirements and enclose all authorized employees conducting work protected by the Warning Line System. See the Warning Line Systems Appendix for details

Safety Monitoring Systems for roofing work only (Construction)

    • NC State employees planning to conduct work protected by a Safety Monitoring System shall document a project safety review, including a job hazard analysis for each task or job, and submit it to Environmental, Health & Safety for review at least 2 weeks prior to the start of work.
    • A Safety Monitoring System may be used in conjunction with a warning line system in lieu of conventional fall protection such as guardrails, a fall protection system, or a safety net system only for roofing work on low sloped roofs.
    • A Safety Monitoring System alone may be used on low sloped roofs less than 50 ft. wide, as determined according to OSHA’s 29CFR1926,M, Appendix A, “Determining Roof Widths,” if the use of a warning line system is infeasible.
    • Refer to the Safety Monitoring Systems for specific information on Safety Monitoring System requirements and Safety Monitor Responsibilities.

Inspections, Investigations, and Assessments Exception (Construction and General Industry)

    • Fall protection is not required when employees are making an inspection, investigation, or assessment of workplace conditions prior to the actual start of work or after all work has been completed.
    • There can be no ongoing work where the inspection is being conducted. Once work starts, fall protection, as described in this procedure is required.
    • If any type of fall protection is available for use by the inspector, including administrative controls, it must be utilized.
    • Refer to the Inspections, Investigations, and Assessments Exception for guidance

 

Personal Protective Equipment

Anchorages and Anchorage Systems

    • An anchorage is a permanent structure that serves as a point of attachment for a personal fall protection system. Anchorages must be designed by a Qualified Person and installed by a Qualified Person or a Competent Person.
    • A competent person shall select the suitable anchorage(s) for each job or task that requires a personal fall protection system.

IMPORTANT NOTE:  Persons competent in selecting proper anchorages may use non-certified anchorages for personal fall arrest or travel restraint.

    • Anchorages for fall arrest, travel restraint, or positioning systems shall be:
      • capable of supporting at least 5,000 pounds per person attached, or
      • designed, installed, and used under the supervision of a qualified person, as part of a complete personal fall protection system that maintains a safety factor of at least two.
    • A lifeline is an anchorage sub-system and is a rope, cable, or shaft held securely by the anchorage, and on which the connector slides. The connector moves freely along, up, or down on the lifeline as long as there is no load on the connector. Examples include horizontal and vertical lifelines and ladder safety systems and can be rigid (track) or flexible (cable).
    • Lifelines, including ladder safety systems and travel restraint systems, may use an arrester as a connection. As soon as there is a load on the arrestor, the arrester locks onto the lifeline and prevents any downward motion.
    • Anchorages and anchorage sub-systems must be properly maintained, inspected annually and physically tested every 10 years or as required by the qualified person.
    • For anchorages for Rope Descent systems used by contractors, e.g.: window washing, the NC State contracting entity shall provide the contractor with a written certification of annual inspection that each anchorage has been identified, tested, certified, and maintained so it is capable of supporting at least 5,000 pounds (2,268 kg), in any direction, for each person attached.

Travel Restraint Systems for low-slope working surfaces (General Industry):

    • Travel restraint systems prevent exposure to fall hazards with the use of PPE including a full body harness and a restricting lanyard. Travel restraint systems are for use in general industry work only, and must be designed to prevent an employee from going over the edge of a fall hazard.
    • Travel restraint systems shall only be used on working surfaces with a downward slope of less than 4:12 (18 degrees) towards the fall hazard.
    • Travel restraint systems consist of an anchorage, an anchorage connector, a restricting lanyard, and a full body harness (NC State requirement) with a lanyard attachment. All components of a travel restraint system must be capable of sustaining a 5,000 lb. load per person. Travel Restraint Anchorage Systems must be designed by a Qualified Person and installed by a Competent Person. Refer to the Travel Restraint Systems Appendix for more information
    • Systems designed exclusively for travel restraint shall not be used for fall arrest or another purpose.

Positioning Systems for vertical working surfaces (General Industry):

    • Positioning systems are similar to travel restraint systems except they do not prevent a fall. They are intended for general industry work and allow an employee to be supported on an elevated vertical working surface, such as a wall or window sill, and work with both hands free.
    • Positioning systems consist of an anchorage, an anchorage connector, a restricting or a self-retracting lanyard, and a full body harness with a lanyard attachment. Positioning systems also are called “positioning system devices” and “work-positioning equipment.”
    • Components of a positioning system shall automatically limit free fall distance to 2 feet or less, and shall be capable of sustaining a minimum tensile load of 5,000 lbs. Positioning System Anchorages must be designed by a Qualified Person and installed by a Competent Person.
    • Refer to the Positioning Systems Appendix for detailed information

Positioning Device Systems for horizontal and vertical work surfaces (Construction):

    • Positioning device systems are similar to positioning systems except they can only be used in construction industry work and can be used on both vertical and horizontal work surfaces.
    • Positioning device systems consist of an anchorage, an anchorage connector, a restricting or a self-retracting lanyard, and a full body harness (NC State requirement) with a lanyard attachment.
    • Components of a positioning device system, except window cleaners’ belt systems, shall automatically limit free fall distance to 2 feet or less.

 

Personal Fall Arrest Systems

Personal Fall Arrest System

    • Must be designed by a qualified person (registered professional engineer) in accordance with state building codes, OSHA 1926 Subpart M Fall Protection, 1910 Subpart D Walking Working Surfaces, and ANSI Z359 Fall Protection Code. All equipment components (full body harness, lanyards, connectors, etc. shall comply with OSHA 1910.140 and 1926, subpart E)
    • Must protect at least 2 users. See Working Alone Policy
    • Must be designed so that 100% protection is provided for all accessed areas or locations where there is a fall hazard.
    • Specification for elements of a personal fall protection system can be found in the Personal Fall Arrest System Appendix.
    • A rescue plan is required, must be written, and provisions to implement the plan immediately available.
    • Users shall be trained on the specific personal fall arrest system they will be using. Training must include a review of the General Design Notes provided by the qualified person, capacity limitations, number of users allowed, and designer specified limitations and procedures on the use of the system.
    • Service and Maintenance. Annual inspections shall be performed in accordance with designer’s specifications; recommend assigning the system an asset number so that a PM schedule can be created in AiM to prompt annual inspection and track inspection history.  The recertification shall be performed according to the qualified person’s specification and interval.
    • Personal Fall Arrest Systems do not prevent employees from falling. The PFAS arrests the fall and prevents the employee from hitting a lower level in a fall. The employee is still subjected to significant forces in the fall and risks suspension trauma.
    • A rescue plan is required for any use of a PFAS to enable a safe rescue and reduce the risk of suspension trauma, should a fall occur. Contact with the rescue subject should occur as soon as possible after the fall, but should be no less than 6 minutes.  At a minimum, rescue plans shall:
      • Be in writing
      • Provide a list of provisions/equipment required to be immediately available and their intended use
      • Identification of specific persons trained to implement the rescue plan
      • Method for communication (phone, radio, hand signals, etc.)
      • Emergency contacts
      • First aid kit (appropriately stocked for anticipated emergencies)
      • Method of retrieval
        1. How to reach the rescue subject(s)
        2. Self rescue procedures
        3. Assisted rescue procedures
        4. If off-site assistance is required, ensure identified and on stand-by to respond immediately
      • Identify hazards to rescuers and methods for elimination/control
      • Post Incident review
      • Ensure rescue plan is reviewed by a competent person at least annually
    • Personal Fall Arrest is the least desirable form of fall protection.
    • Components of a personal fall arrest system shall be capable of sustaining a minimum tensile load of 5,000 lbs per user. Except that a self-retracting lanyard must have a tensile strength of 3,000 lbs. Anchorages and lanyards used in construction must have a breaking strength of 5,400 lbs. PFAS Anchorages must be designed by a Qualified Person and installed by a Competent Person.

Rope Descent System (RDS)

    • NC State employees planning to conduct work protected by a Rope Descent System shall document a project safety review, including a job hazard analysis for each task or job, and submit it to Environmental, Health & Safety for review at least 2 weeks prior to the start of work.
    1. Other Methods of Fall Protection
      • Safety Nets: Safety Nets are a type of conventional fall protection that catch employees after a fall. Safety nets are complex assemblies designed and installed by a Qualified Person for each specific application. They must be tested daily and meet other specific regulatory requirements. Safety Nets are not addressed in this procedure. Please contact EHS, env-health-occ-safety@ncsu.edu for further information if needed.